Special Welding

SPECIAL WELDING
PROCESSES
1. ROLL WELDING
2. ULTRASONIC WELDING
3. GAS PRESSURE WELDING
4. MAGNETICALLY IMPELLED ARC WELDING
ROLL WELDING (ROW)
# Roll welding is a solid state welding process which produces
coalescence of metals by heating and by applying pressure with rolls
sufficient to cause deformation at the faying surfaces
# Pressure is applied by means of rolls
# Coalescence occurs at the interface between the two parts by

means of diffusion at the faying surfaces
# One of the major uses of this process is the cladding of mild or

low-alloy steel with a high-alloy material such as stainless steel
# It is also used for making bimetallic materials for the instrument

industry
Two modes of roll welding are common
1. In the first, the parts to be welded are merely stacked and

passed through the rolls
2. The second method, usually termed pack rolling, involves sealing

the parts to be rolled in a pack or sheath and then roll welding the
pack assembly
Applications
One of the more important applications of roll welding is the
fabrication of heat exchangers
Ultrasonic welding (USW)
# Ultrasonic welding is a solid state welding process which produces
coalescence by the local application of high- frequency vibratory
energy as the work parts are held together under pressure
# Welding occurs when the ultrasonic tip or electrode, the energy

coupling device, is clamped against the work pieces and is made to
oscillate in a plane parallel to the weld interface
# The combined clamping pressure and oscillating forces

introduce dynamic stresses in the base metal
# This produces minute deformations which create a moderate

temperature rise in the base metal at the weld zone
# This coupled with the clamping pressure provides for coalescence
across the interface to produce the weld
# Ultrasonic energy will aid in cleaning the weld area by breaking

up oxide films and causing them to be carried away
# The vibratory energy that produces the minute deformation

comes from a transducer which converts high-frequency alternating
electrical energy into mechanical energy
# The transducer is coupled to the work by various types of tooling

which can range from tips similar to resistance welding tips to
resistance roll welding electrode wheels
# The normal weld is the lap joint weld

# The temperature at the weld is not raised to the melting point
and therefore there is no nugget similar to resistance welding
# Weld strength is equal to the strength of the base metal
# Most ductile metals can be welded together and there are many
combinations of dissimilar metals that can be welded
# The process is restricted to relatively thin materials normally in

the foil or extremely thin gauge thicknesses
# This process is used extensively in the electronics, aerospace,

and instrument industries. It is also used for producing packages
and containers and for sealing them
The advantages
 PERMITS JOINING OF THIN MATERIALS TO THICK MATERIALS
 PERMITS DISSIMILAR METAL JOINTS
 PROVIDES JOINTS WITH GOOD THERMAL AND ELECTRICAL CONDUCTIVITY
 JOINS METALS WITHOUT THE HEAT OF FUSION
 PROVIDES EFFICIENT ENERGY USE
 TYPICALLY REQUIRES NO FILLER MATERIAL, FLUX, OR SPL ATMOSPHERE
 TYPICALLY REQUIRES NO SPECIAL CLEANING PROCESSES
 WELDS THROUGH MOST OXIDES

Applications
Commercially successful applications generally have certain

characteristics
# First, joints must be lap joints, not butt joints

# Second, thin sections are required adjacent to the
welding tip
# Third, better results are obtained with nonferrous alloys
Production applications include electrical wire harnesses for the

appliance and automotive industry; buss bars; fuses; circuit breakers;
contacts; ignition modules; starter motors; aluminum and copper foil;
battery foils; capacitors; encapsulation of explosives; microelectronic
wires; heating, ventilation, and air conditioning (HVAC) tubing; and
many others.
Pressure Gas Welding
MAGMETICALLY IMPELLED ARC WELDING (MIAB)
# An alternative technique to resistance, butt, flash and friction

welding processes
# MIAB can reduce welding time by up to 90%, cut out the need to
rotate components and weld circular or non-circular components
with the same ease
# Any angular orientation can be welded
# The process can be used to weld steels, stainless steel,

aluminium alloys, etc.
# MIAB welding uses a magnetic field to rapidly scan a welding arc
along a joint
# The result is one of the fastest methods of welding tube to tube

and tube to flange
# This welding process offers large cost savings for a range of joint
configurations
# Mobile MIAB machines can be used on site and allow transmission

pipelines to be welded with potential savings due to improved
productivity over other arc welding processes.
Two stages
Gap = 1- 3 mm
Benefits
 Autogenous - no filler material required
 No rotation of either component
 Low material loss
 Low power consumption
 Low fume emission
 Low distortion
 Ease of automation
Examples of components already production welded using the MIAB
process:
 vehicle drive shafts

 rear axle assemblies
 wheel bearing housings pipe and tube assemblies
 shock absorber assemblies
 brake pipes
 heat exchanger assemblies
 threaded sleeves assemblies
 nuts welded to plates
 filter case manufacture
 pressure vessel manufacture

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SPECIAL WELDING

# Pressure is applied by means of rolls

# Coalescence occurs at the interface between the two parts by

# One of the major uses of this process is the cladding of mild or

# It is also used for making bimetallic materials for the instrument

1. In the first, the parts to be welded are merely stacked and

2. The second method, usually termed pack rolling, involves sealing

# Welding occurs when the ultrasonic tip or electrode, the energy

# The combined clamping pressure and oscillating forces

# This produces minute deformations which create a moderate

# Ultrasonic energy will aid in cleaning the weld area by breaking

# The vibratory energy that produces the minute deformation

# The transducer is coupled to the work by various types of tooling

# The normal weld is the lap joint weld

# Weld strength is equal to the strength of the base metal

# The process is restricted to relatively thin materials normally in

# This process is used extensively in the electronics, aerospace,

 PERMITS JOINING OF THIN MATERIALS TO THICK MATERIALS

 PERMITS DISSIMILAR METAL JOINTS

 PROVIDES JOINTS WITH GOOD THERMAL AND ELECTRICAL CONDUCTIVITY

 JOINS METALS WITHOUT THE HEAT OF FUSION

 PROVIDES EFFICIENT ENERGY USE

 TYPICALLY REQUIRES NO FILLER MATERIAL, FLUX, OR SPL ATMOSPHERE

 TYPICALLY REQUIRES NO SPECIAL CLEANING PROCESSES

 WELDS THROUGH MOST OXIDES

Commercially successful applications generally have certain

# First, joints must be lap joints, not butt joints

Production applications include electrical wire harnesses for the

# An alternative technique to resistance, butt, flash and friction

# Any angular orientation can be welded

# The process can be used to weld steels, stainless steel,

# The result is one of the fastest methods of welding tube to tube

# Mobile MIAB machines can be used on site and allow transmission

 vehicle drive shafts

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